Wireless and Modular Data Collection System with Sensor Ic Integration Capability

The present application relates to the field of data collection systems used in industrial settings. More specifically, it pertains to a versatile data collection for engineers and other professionals enabling efficient and adaptable data gathering across various industrial applications.

In industrial settings, data collection is crucial for monitoring, analyzing, and optimizing various processes and equipment. Traditionally, industrial data collection has relied on specialized instruments and manual methods, which can be cumbersome and inflexible. Many existing systems require dedicated hardware for each type of sensor or data source, leading to increased complexity and difficulty in integrating new sensors or adapting to changing requirements.

1. Limited Versatility: Conventional systems are typically designed for specific types of sensors or data sources, making it challenging to incorporate new or different sensors without significant modifications. 2. Complex Integration: Integrating various sensors into a unified system often involves complex wiring and setup, which can be time-consuming and error-prone. 3. Scalability Issues: Many traditional systems are not easily scalable, making it difficult to expand the data collection network as new sensors or data points are added. 4. Lack of Adaptability: Existing systems may not easily adapt to different industrial applications or environments, reducing their overall utility. Existing data collection systems often suffer from several limitations:

Therefore, there is a need for a more versatile and adaptable data collection system that can seamlessly integrate with various types of sensors, simplify the setup and integration process, and easily scale to accommodate new data sources. Such a system would enhance the efficiency and effectiveness of data collection in industrial settings, providing engineers and professionals with a more flexible and user-friendly tool for managing their data.

The present invention addresses these needs by providing a versatile data collection system designed to function as a “multi-tool,” capable of integrating with a wide range of sensors and data sources while offering a streamlined and adaptable solution for industrial data collection.

The disclosed embodiment of the system depicts the basic architecture of the system. In one diagram, an overall view is provided, showing what makes up the system as a whole and by what means each part of the system communicates with each other.

The other diagram depicts just a sensor node in order to demonstrate how the actual sensor is interchangeable as long as the microcontroller is programmed to accommodate. This allows any sensor type to be easily integrate-able into the system.

In the following detailed description, the system according to the teachings for this application will be described following the diagram. It should be noted that even though the system architecture in these teachings is described in terms of a data acquisition system, it can be used for many web to network of hub managed device applications.

1 FIG. 100 101 102 101 2 200 2 101 102 1 102 103 4 4 3 102 300 301 301 302 303 303 301 303 300 102 In., the hub, manages the hardware system. The hub has two WiFi and internet capable microcontrollersand. Microcontrollermanages the WiFi mesh network. It coordinates sending of data and receives data from a network of sensor nodes. Use of a mesh networkallows extended range and lower potential for data loss. Microcontrolleralso after receiving data passes it to microcontrollerover serial interface. The specific serial interface isn't extremely important, I2C or UART has been used. Microcontrollercaches data to a local data cache, for which a flash chip has been used, over serial interface. For serial interface, SPI is typically used. Over internet connection, either through WiFi or ethernet, microcontrollersends the packaged data to network accessible serverwith a datarouter. The datarouterroutes the data to the database. An end user can access a data interface with live graphs and historical data through a webpage serving user interface. User interfacecan interact with the datarouterin order to pull live and historical data. It is worth noting that the user interfacecan through the network accessible serverpass commands to microcontrollerwhich allows control over essential hub functions remotely.

2 FIG. 1 FIG. 200 201 200 2 202 202 201 101 101 200 200 In., the sensor nodeis depicted. Microcontrolleris what allows the sensor nodeto communicate on the mesh networkdepicted in.. The microcontroller can be programmed to package any type of data received from a sensing implementinto an acceptable format for it to be transmitted on the mesh network. Data from the sensing implementcan be anything as long as the microcontroller chosen has the facilities to accommodate (ADC, SPI, I2C, UART). This is what gives the system its versatility and allows it to accommodate any data type. The microcontrollercan also be programmed to recognize and authenticate itself on the mesh network, if the mesh network managed by microcontrolleraccommodates it. If microcontrollerallows any connection but requires connecting microcontrollers to authenticate themselves with an encrypted passkey, sensor nodescan automatically connect themselves, allowing the end user to have no need to set up sensor nodes. If a sensor nodeautomatically connects when it powers on through this system, it adds another level of convenience for the end user.

100 200 When manufactured, both the huband sensor nodesit on separate PCBs. Firmware for all microcontrollers has not been explicitly described but because the general function is, those skilled in the art are able to reproduce the general function. Furthermore, the mediums of communicating in the system has not been specified, only generally referred to, because the function of the system is not contingent on the type of medium.